System And Method For Multiple Layer Coil Winding

ABSTRACT

The device for winding multiple layered material has a first shaft and a second shaft. A plurality of coils having a width are mounted to the first shaft. At least one guide is mounted between the first and second shafts. The guide has at least one slot with a horizontal surface and two vertical surfaces on each side of the horizontal surface. The second shaft has two flanges spaced apart at least as wide as the width of the plurality of coils. The slot in the guide receives at least one of the strips from the coils. Each strip from each coil is layered around the second shaft.

FIELD OF THE INVENTION

The present apparatus and method is directed to winding multiple coilsof material strip into a single coil of multiple layers. The system maybe used for a wide variety of materials such as metals, plastics andother materials, which may be wound into coils. The apparatus and methodmay also be used to wind multi layer coils around a single drum tocreate a coil with a larger number of layers.

BACKGROUND OF THE INVENTION

Long strips of material often come in coils of a single layer. In someinstances, the coils originate from a wider coil of material that hasbeen cut into narrower strips according to the specifications of thecustomer or the manufacturing process that will use the material.Machines in the prior art typically only create multiple coils of asingle layer and do not wind multiple coils of material into a singlecoil having multiple layers. Therefore, if a customer desires a feedstock of material having multiple layers of material strip, prior artmachines do not solve the problem of how to wind multiple coils into asingle coil in an efficient or economically feasible way.

U.S. Pat. No. 1,534,988 to Perrault discloses a system for cutting aflexible material into multiple strips and superposing those strips uponeach other, creating multiple layered roll. Perrault does not disclose aguide or flanges to retain and orient the strips. Thus, there is risk ofthe strips winding improperly. In addition, the machine described inPerrault takes a generally horizontal feed stock material, slits thatmaterial into narrow ribbons, vertically orients the narrow ribbons andthen rolls the ribbons in a vertical orientation. Re-orienting theribbons could cause too severe of a bend in many materials and would notbe appropriate for all material applications. In addition, Perrault doesnot disclose winding more than four layers around a single drum.

U.S. Pat. No. 6,704,988 to Kenney et al. describes a method of making acontinuous laminate coil. Kenney discloses a shaft to receive aplurality of layers of material. The plurality of layers comprised of atleast three different types of material. The layers are then diffusionbonded to create a continuous laminate coil. Kenney does not disclose aguide having a slot for each individual coil. Further, Kenney does notdisclose any means to guide the individual coils around a single drum.Further, each individual coil is on a different shaft, which requires anentirely new machine to wind a multiple layer coil, rather than aretrofitted guide and flanges on slitting machines.

U.S. Pat. No. 4,093,140 to Matsunaga discloses a method by whichmultiple strands of slit metal material are wound around a rotating drumof a recoiler. Frictional contact between the recoiler drum and strandsallow relative movement between the recoiler drum and the separatecoils. This frictional contact allows for each individual strand to bewound at substantially the same speed. Matsunaga does not disclose anymeans to guide the individual coils around a single drum. Further, aguide is not disclosed, and flanges around one of the drums are notdisclosed.

U.S. Pat. No. 2,399,155 to Reed et al. discloses a system and method forslitting and recoiling the slit metal material. The metal strip is fedunder tension into a slitting machine. Once the metal leaves theslitting machine, it is de-tensioned and fed through a rotary tensioningdevice. The rotary tensioning device provides constant tension betweenthe metal strip and each individual recoil drum. Reed does not discloseany means to guide the multiple coils around a single drum. Further,Reed does not disclose a guide or flanges to aid in winding multiplecoils around a single drum.

It is therefore desired to provide an improved apparatus and method tomanufacture a multiple layer coil, which overcomes the disadvantages ofthe prior art.

It is further desirable for such an improved apparatus to be retrofittedto existing slitting machines, reducing the capital expenditure requiredto manufacture a multiple layer coil. Such an apparatus would furtherovercome the disadvantages of the prior art.

SUMMARY OF THE INVENTION

An object of the present invention is to provide an apparatus forwinding multiple layers of single layer coil around a single drum tocreate a multiple layer coil.

Another object of the present invention is to further wind a pluralityof multiple layer coils around a single drum to create a coil with evenmore layers.

Another object of the present invention is to retrofit existing slittingand/or winding with guides and flanges to wind multiple layer coils.

Another object of the present invention is to provide a method forwinding multiple layers of single coil around a single drum to create amultiple layer coil.

Another object of the present invention is to provide a method forfurther winding a plurality of multiple layer coils around a single drumto create a coil with more layers.

Another object of the present invention is to provide a method forretrofitting existing slitting machines and/or winding machines withguides and/or flanges to create a machine for coiling multiple layers ofmaterial.

Another object of the present invention is to utilize existing coil andclutch assemblies used in slitting machines to create an even tensionacross each individual strip to aid in an evenly wound multiple layercoil.

The objects of the invention are achieved by a device having two shaftsand plurality of coils mounted around the first shaft, each of theplurality of coils having a width. A guide mounted between the first andsecond shafts has at least one slot, each slot having a horizontalsurface and two vertical surfaces. The two vertical surfaces are locatedadjacent to the horizontal surface. The second shaft has two flangesspaced apart a distance at least as wide as the width of each of theplurality of coils. The slots in the guide receive at least one stripfrom the plurality of coils, and the slots may receive more than onestrip depending on the requirements of the multiple layer coil. Thefirst strip from the first coil extends around the second shaft andbetween the flanges. A second strip from a second coil extends betweenthe flanges such that the second strip is layered onto said first strip.Each additional strip is layered on top of a preceding strip.

The second shaft has a drive mechanism for rotating the second shaft,and the first shaft has a brake mechanism for resisting the rotation ofthe coils. The drive and brake mechanisms are activated such thattension is created along each coil. The guide may be positioned suchthat said tension along each coil creates a vertical force along thehorizontal surface of the guide slot(s).

The guide can also have an angled surface on either side of thehorizontal surface. The angled surface is angled down from thehorizontal plane. Further, there is an angled surface on either side ofthe vertical surface. The angled surface is angled out from the verticalplane.

A cover may be removably attached on the top of the guide. Additionally,more than one strips of material may be placed in each guide slot. Thedevice may be retrofitted to existing equipment, such as a slittingmachine.

The device can have clutch members mounted between the plurality ofcoils and on the first shaft. Tension is created when the second shaftis driven to wind the multiple layers of coil and the first shaftresists the rotational force. The clutch members provide frictional slipnecessary to equalize the tension in each individual strip of each coil.

The device may also have a second guide having a slot with a horizontalsurface and a vertical surface on either side of the horizontal surface.The second guide is located between the first guide and the secondshaft. The slot in the second guide receives every strip from theplurality of coils, the strips layered on top of each other. A cover maybe removably attached on top of the second guide.

Any of the guides may also be a solid block with the guide slotscharacterized by a void of material passing through the solid block.

Further objects of the present invention are achieved by providing amethod for winding a multiple layer coil. The method uses a number ofsteps. Mounting a plurality of material coils on a first shaft, feedingeach material coil through a guide having a plurality of slots, eachslot having a horizontal surface and at least two vertical surfaces, thevertical surfaces located adjacent to each said horizontal surface. Eachcoil is attached to a second shaft between two flanges. The second shaftis driven such that the shaft rotates. Braking is applied to the firstshaft to resist the rotation of the second shaft. The driving andbraking produces tension along the strip, this tension creates avertical force on the horizontal surface of the guide. The second shafthas flanges that align the plurality of coils such that a multiple layercoil is created. Mounting the plurality of coils may include the step ofmounting clutch members between the plurality of coils. Further, thesame method may be used with a plurality of multiple layer coils mountedto the first shaft, with the method being used to create a multiplelayer coil with even more layers.

Other objects of the invention and its particular features andadvantages will become more apparent from consideration of the followingdrawings and accompanying detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a slitting machine retrofitted to coilfour layers of material around a single drum.

FIG. 2 is a perspective view of a guide element of the slitting machineshown in FIG. 1.

FIG. 3 is a top view of the guide shown in FIG. 2.

FIG. 4 is a section view of the guide shown in FIG. 3. The section lineis shown in FIG. 3.

FIG. 5 is a top view of the retrofitted slitting machine in FIG. 1.

FIG. 6 is an exploded view of another guide element of the slittingmachine shown in FIG. 1.

FIG. 7 is a perspective view of another guide element of the slittingmachine of in FIG. 1.

FIG. 8 is a top view of the slitting machine shown in FIG. 1 including asecondary guide.

FIG. 9 is an exploded perspective view of the secondary guide shown inFIG. 8.

DETAILED DESCRIPTION OF THE INVENTION

The invention relates to thin-coiled strips of material. The materialmay be metallic, plastic or other materials. In a preferred embodimentthe invention relates to rolled metal coil. Rolled metal coil usuallycomes in wide widths. Often, it is desirable to have narrower coils ofthinner material. The wide material is often fed through a rollingmachine, which reduces the thickness. Then, the wide material is fedthrough a slitting machine, which cuts the wide roll into multiplenarrow strips of material. The apparatus and method described hereinwinds the plurality of coils into a single coil with a plurality oflayers. The existing slitting machine may be retrofitted to wind amultiple layer coil.

In some instances, it is desirable to have a material of multiple layersin a single coil. For example, four coils of aluminum could havedimensions of 0.005″ thickness and 1.00″ width. These four coils wouldbe rewound onto a single drum, resulting in a final coil that would, inthis example, have a thickness of four sheets (0.020″) and a width of1.00″. There are many possible configurations for the winding process.Another example would be a guide having four slots and two strips ofmaterial passing through each slot. This example would result in amultiple layer coil of eight (8) layers.

To wind the multiple coils into one multiple layer coil, a slittingmachine is fitted with multiple coils on one shaft, and a single drum ona second shaft. The strip from the metal coils is fed across the machinefrom one shaft to the other, and through a guide with multiple slots.The guide directs each strip towards the single drum on the oppositeside of the machine.

The single drum has flanges fitted on either side. These flanges arespaced apart to accommodate the width of the strip. The flanges act asan additional guide to ensure that the multiple layers of strip arealigned properly with the drum.

Each strip is attached around the single drum in a layered formation,with one strip on top of the next. The strips are removably attached tothe drum. In some embodiments, the first strip is removably attached tothe drum and each additional strip is removably attached to thepreceding strip. The removable attachment can be with tape, glue,friction winding, clamps or other means known to one of ordinary skillin the art. In some embodiments, the strips may also be wound the singledrum either in individual winds or a collective wind. The friction ofthe winding holds the individual strips on the drum so that the drum canbe driven to create tension on the strips to pull the strips through theguide and around the single drum.

In one embodiment of the invention, each slot of the guide has ahorizontal surface. There are two surfaces, one on each side of thehorizontal surface, these two surfaces are angled down from thehorizontal plane. Further, each slot has two vertical surfaces. There isan angled surface on either side of each vertical surface, these angledsurfaces are angled out from the vertical plane.

The strip is placed under tension between the two shafts, and the guideis placed in a location such that the tension along the strip imparts avertical force on the guide. For example, the position of the guide onthe winding machine is such that the metal coil travels across and up toa guide slot and then across and down to the single drum. The positionof the guide allows for tension on the strip of metal to hold theindividual coils within the individual guide slots during the multiplelayer re-winding. This vertical force prevents each strip from comingout of the guide. The vertical surfaces in each guide slot contact theedge of the strip to bring the strip inwards towards the alignment ofthe single drum.

Although the preceding example references the strip travelingvertically, the machine may be oriented such that the strip travelshorizontally, as long as tension on the strip imparts a force on theguide to help keep the strip in the guide slot.

By utilizing the slitting machine to re-wind a multiple layeredmaterial, the process can be completed by winding the coils in thereverse direction of the slitting machine immediately after the widecoil has been slit into multiple coils of narrow material. To accomplishthis, the full coil is mounted to the payoff and is run through theslitter and re-winder to create multiple narrow coils. Before slitting,narrow coils are mounted on slip clutch tooling to accommodate differinginternal tension of the rolled strip. Once the wide material is cut intonarrow strips, the slitting cutters are removed and a guide is put intheir place. The narrow strips are then fed through the guide and a drumhaving flanges as described above. This allows for a more continuousprocess of winding a multiple layer coil than if a specialized machinewere used just for the multiple layer winding.

In one embodiment of the present invention, the guide slots are closedon top such that an additional horizontal surface is between thevertical surfaces of each guide slot and opposite the horizontal surfacethat contacts the strip material.

In another embodiment of the present invention, the guide includes aremovable cover that mounts flush with the top surface of the guide.This removable cover allows the operator to place the strips in theguide slots and then place a cover on top to prevent the strips fromcoming out of the slots.

Each guide slot may accept more than one strip of material. The heightof the guide slot or alternatively the depth of the guide slot may needto be adjusted to accommodate two or more strips in a single slot. Aguide can also be made with only one slot to accept material. To wind amultiple layer material using a guide having a single slot, the singleslot will accept more than one strip of material.

A plurality of winding drums may be mounted to the slitting machine towind more than one multiple layer coil in one process. For example,eight (8) coils on slip clutch tooling are mounted to one shaft, and twoguides are placed in the middle of the slitting machine. The guides eachhave four slots, and a strip is placed in each slot. The strips from theseparate guides are wound around separate drums to create a finalproduct of two coils each having four layers of material. Alternatively,the guide in this example may also be made with eight slots, the firstfour slots being wound around the first drum and the next four slotswound around the second drum. The groups of four described above shouldnot limit the scope of the invention to multiples of four. The multiplesof four are used for example only, and multiples of 2, 3, 4, 5 and upare contemplated in the scope of this invention. A coil of eight (8)layers may also be made with one guide having four (4) slots. Eachsingle layer coil is fed through a guide slot, each guide slot receivestwo (2) single layer coils. All eight single layer coils are woundaround a single drum to create an eight (8) layer coil.

The guide can be made from a material that will minimize scratches onthe surface of the metal. The finish on the guide is also designed tominimize scratches on the surface of the metal. In one embodiment of theinvention, the guide is made from UHMW Polyethlyene.

The single coil that receives the multiple layers of metal is fittedwith flanges on either side. The flanges act as another guide for themultiple layers of metal to ensure alignment of the multiple strips withthe drum.

The machine may be fitted with a secondary guide that is also locatedbetween the two shafts. This secondary guide has one slot for receivingall layers of material to be wound around the single drum. Thissecondary guide may further be fitted with a cover on top to help keepthe material within the guide slot. The secondary guide is moreimportant as the width of the strip is larger and/or the distancebetween the two shafts is shorter. A wider strip means that the overallwidth of the stack of multiple coils is larger, which requires that theouter strip travel inwards to the single drum a greater distance(equivalently a greater angle) than in the case of narrower strips. Byusing a secondary guide, it can be easier to align multiple stripsbefore winding. The same holds true when the distance between shafts isshorter, the angle that the outer strip must travel is greater, thus asecondary guide can be advantageous.

FIG. 1 is a perspective view of a slitting machine retrofitted to coilfour layers of material around a single drum. A first shaft 2 is fittedwith a plurality of coils 8. These coils are fed through a guide 10. Thecoils 8 are then stacked around a single drum 14. The single drum ismounted to a second shaft 4. On either side of the single drum, thereare flanges 12 spaced apart to accommodate the width of the coils 8. Thesecond shaft 4 is driven by a motor 19. The first shaft 2 is also drivenby a motor 20. Typically, this motor 20 is used in reverse to resistrotation of the coils 8. This resistance causes tension in the strip 9.

Since the guide 10 is mounted above the coils 8 and the multiple layers6 by a distance 18, the tension in the strip 9 creates a downward forceon the guide 10. The downward force holds each individual strip in theguide 10 during the rewinding process. As shown in FIG. 1, the height ofthe guide 10 may be adjustable using height adjustment mechanisms 16located on each side of a base of the guide 10.

FIG. 2 is a perspective view of the guide 10 shown in FIG. 1. FIG. 2shows a guide 10 having four individual slots defined between aplurality of vertical ribs or teeth 30, each slot receiving a strip ofcoiled material as disclosed in FIG. 1. Each slot has a generallyhorizontal surface 22. On either side of horizontal surface 22 is anangled horizontal surface 26 that is angled down from the horizontalplane. On either side of the horizontal surface 22, there is a verticalsurface 24. On either side of the vertical surface 24, there is anangled vertical surface 28 that is angled out from the vertical plane.The guide 10 has holes 21 for mounting the guide 10 to the slittingmachine and/or the height adjustable base 16 as shown in FIG. 1.

FIG. 3 is a top view of the guide shown in FIG. 2. Angles 32 and 34 areshown as the angle between the vertical surface 24 and angled verticalsurface 28. In one embodiment of the present invention, the angles 32and 34 are 10 degrees.

FIG. 4 is a section view of the guide shown in FIG. 3. The section lineis shown in FIG. 3. The Angle 42 is shown as the angle created by thehorizontal surface 22 and the angled horizontal surface 26. In oneembodiment of the present invention, the angle 42 is 15 degrees.

FIG. 5 is a top view of the slitting machine shown in FIG. 1. Shaft 2 isfitted with coils 8. On either side of each coil is a clutch device 52.The coils 8 are mounted to the shaft, and the bolt 54 is tightened. Bytightening bolt 54, a force normal to each clutch device 52 is created,rotational frictional resistance from each clutch device 52. When shaft4 is driven and shaft 2 partially resists the rotational movementimparted by shaft 4, the each clutch device 52 distributes the totaltension along the four strips 9 evenly between each strip. The evendistribution of the tension aids for an even winding of the layers ofmaterial.

FIG. 6 is an exploded view of the guide 10 shown in FIG. 1 with anoptional cover 60. FIG. 6 shows a guide 10 having four individual slotsdefined between a plurality of vertical ribs or teeth 30, each slotreceiving a strip of coiled material as disclosed in FIG. 1. Each slothas a generally horizontal surface 22. On either side of horizontalsurface 22 is an angled horizontal surface 26 that is angled down fromthe horizontal plane. On either side of the horizontal surface 22, thereis a vertical surface 24. On either side of the vertical surface 24,there is an angled vertical surface 28 that is angled out from thevertical plane. The guide 10 has holes 21 for mounting the guide 10 tothe slitting machine shown in FIG. 1. The cover 60 includes two or moreholes 62. Bolts 64 pass through the holes 62 and through holes 21 tomount the guide and cover to the slitting machine shown in FIG. 1. Whenmounted to the slitting machine as described, the cover 60 is flush withthe top surface 66 of the guide 10. The cover 60 prevents the strip fromcoming out of the guide 10 during the multiple layer winding process.

FIG. 7 is a perspective view of an alternative embodiment of the guideshown in FIG. 1. FIG. 7 shows a guide that is similar to the assembledguide of FIG. 6, however the top cover is not removable. The guide hasfour individual slots, each slot receiving a strip of coiled material asdisclosed in FIG. 1. Each slot has a generally horizontal surface 72. Oneither side of horizontal surface 72 is an angled horizontal surface 76that is angled down from the horizontal plane. On either side of thehorizontal surface 72, there is a vertical surface 74. On either side ofthe vertical surface 74, there is an angled vertical surface 78 that isangled out from the vertical plane. The guide has holes 71 for mountingthe guide to the slitting machine shown in FIG. 1.

FIG. 8 is another top view of the slitting machine of FIG. 1 includingan additional guide element. In addition to the elements shown in FIG.5, there is a secondary guide 82 located between shafts 2 and 4. Thesecondary guide 82 receives all strips 9 in a single slot. The secondaryguide 82 may be mounted to a height adjustable base. For example, aheight adjustable base for the secondary guide may be configured asshown by the height adjustment base 16 shown in FIG. 1.

FIG. 9 is an exploded perspective view of the secondary guide 82 that isshown in FIG. 8. The secondary guide 82 has a slot with a horizontalsurface 92. On either side of the horizontal surface 92, there is anangled horizontal surface 94. Adjacent to the horizontal surface 92 andangled horizontal surfaces 94, there are vertical surfaces 96 and angledvertical surfaces 98. A cover 91 is affixed to the top of the guide 82with bolts 93. The bolts 93 also affix the guide to the multiple layerwinding machine shown in FIG. 8. In some embodiments of the invention,the cover 91 may be omitted.

Although the invention has been described with reference to a particulararrangement of parts, features and the like, these are not intended toexhaust all possible arrangements or features, and indeed manymodifications and variations will be ascertainable to those of skill inthe art.

What is claimed is:
 1. A device for winding multiple layered materialcomprising; a first shaft and a second shaft; a plurality of coilsmounted around said first shaft, each of said plurality of coils havinga width; at least one guide between said first and said second shaft,said guide having at least one slot, each said slot having a horizontalsurface and two vertical surfaces, said two vertical surfaces locatedadjacent to said horizontal surface; said second shaft having twoflanges, said flanges spaced apart a distance at least as wide as thewidth of each of the plurality of coils; each said slot in said guidereceiving at least one strip from said plurality of coils, wherein afirst strip from a first coil extends around said second shaft andbetween said flanges and a second strip from a second coil extendsbetween said flanges such that said second strip is layered onto saidfirst strip.
 2. The device of claim 1 further comprising, eachadditional strip is layered on top of a preceding strip.
 3. The deviceof claim 1, wherein said second shaft comprises a drive mechanism forrotating said second shaft, and said first shaft comprises a brakemechanism for resisting the rotation of said plurality of coils; saiddrive mechanism is activated such that tension is created along eachcoil.
 4. The device of claim 3 wherein said guide is positioned suchthat said tension along each coil creates a vertical force along eachsaid horizontal surface of said guide slot.
 5. The device of claim 1wherein said guide is positioned such that said tension along each coilcreates a vertical force along each said horizontal surface of saidguide slot.
 6. The device of claim 1 further comprising; each said guideslot having a first and second angled surface on either side of saidhorizontal surface, said first and second angled surface angled downfrom the horizontal plane, each said guide slot having an angled surfaceon either side of each said vertical surfaces, said angled surfaceangled out from the vertical plane.
 7. The device of claim 1 wherein acover is removably attached on the top of said guide.
 8. The device ofclaim 3 wherein a cover is removably attached on the top of said guide.9. The device of claim 1 wherein more than one strips of material areplaced in each guide slot.
 10. The device of claim 3 wherein more thanone strips of material are placed in each guide slot.
 11. The device ofclaim 1 wherein the guide has four slots.
 12. The device of claim 3wherein the guide has four slots.
 13. The device of claim 1 wherein saidguide is retrofitted to a slitting machine.
 14. The device of claim 2wherein said guide is retrofitted to a slitting machine.
 15. The deviceof claim 1 further comprising clutch members mounted between saidplurality of coils and on said first shaft.
 16. The device of claim 15wherein the second shaft is driven to wind multiple layers of coil andsaid first shaft resists the rotational force created by said secondshaft, said resistance creating tension along each coil, said clutchmembers providing frictional slip necessary to equalize the tension ineach individual strip of each coil.
 17. The device of claim 2 furthercomprising clutch members mounted between said plurality of coils and onsaid first shaft.
 18. The device of claim 17 wherein the second shaft isdriven to wind multiple layers of coil and said first shaft resists therotational force created by said second shaft, said resistance creatingtension along each coil, said clutch members providing frictional slipnecessary to equalize the tension in each individual strip of each coil.19. The device of claim 1 further comprising; a second guide, saidsecond guide having a slot with a horizontal surface and a verticalsurface on either side of said horizontal surface, said second guidelocated between the first guide and the second shaft, said slot in saidsecond guide receiving every strip from said plurality of coils, saidstrips layered on top of each other.
 20. The device of claim 19 whereina cover is removably attached on top of said second guide.
 21. A devicefor winding multiple layered material, comprising: a first shaft, asecond shaft and a plurality of coils, said coils mounted around saidfirst shaft, said first shaft passing through an inner diameter of eachcoil; at least one guide, said guide having a plurality of slots, eachsaid slots characterized by a void of material passing through saidguide, said guide located between said first and second shafts; saidsecond shaft having two flanges, said flanges spaced apart a distance atleast as wide as a width of said plurality of coils; and each saidplurality of slots in said guide receiving said strip from said coil, afirst strip from the first coil attached to said second shaft, a secondstrip from the second coil attached such that said second strip islayered on top of said first strip.
 22. The device of claim 21 furthercomprising, each additional strip is layered on top of a precedingstrip.
 23. The device of claim 21 wherein said second shaft comprises adrive mechanism for rotating said second shaft, and said first shaftcomprises a brake mechanism for resisting the rotation of said pluralityof coils; said drive mechanism activated such that tension is createdalong each coil.
 24. The device of claim 23 wherein said guide ispositioned such that said tension along each coil creates a verticalforce along each said horizontal surface of said guide slot.
 25. Thedevice of claim 21 wherein said guide is positioned such that saidtension along each coil creates a vertical force along each saidhorizontal surface of said guide slot.
 26. A method for winding amultiple layer coil, comprising the steps of: mounting a plurality ofmaterial coils around a first shaft: feeding each said material coilthrough a guide having a plurality of slots, each slot having ahorizontal surface and at least two vertical surfaces, the verticalsurfaces located adjacent to each said horizontal surface: attachingeach said coil between two flanges on a second shaft; driving saidsecond shaft such that said second shaft rotates: braking said firstshaft such that each coil resists rotation, said driving and braking ofsaid shafts creating tension along each said material coil, said tensionproducing a vertical force on each said horizontal surface to hold saidcoil in each slot of said guide, said guide and said flanges aligningsaid plurality of coils with said single drum to create a multiple layercoil.
 27. The method of claim 26 wherein mounting a plurality ofmaterial coils around a first shaft further comprises the step ofmounting clutch members between the plurality of coils.
 28. The methodof claim 26 wherein said plurality of material coils mounted to saidfirst shaft are multiple layer coils.
 29. The method of claim 27 whereinsaid plurality of material coils mounted to said first shaft aremultiple layer coils.
 30. The method of claim 26 wherein at least oneguide slot receives material coil from two or more coils.